Assembly machine constructed with a light-weight module

ABSTRACT

A plurality of modules of sufficiently light weight (&lt;80 lbs) are assembled end-to-end to construct an assembly machine for performing desired operations on a series of workpieces. A supporting spine underlies the interconnected modules and supports them and associated equipment in the desired array. The modular construction permits the assembly machine to be reconfigured as needed should operational alterations require it, including, but not limited to, the cannibalization of the machine with the modules being usable in constructing a machine having entirely different characteristics.

This application is a continuation of application Ser. No. 11/238,003filed Sep. 28, 2005.

BACKGROUND AND SUMMARY OF THE INVENTION

The present invention is directed to the field of multiple stationassembly machines. More particularly, the present invention is directedto an assembly machine constructed with a light-weight, module and withmodular interconnecting supports which permits construction of a varietyof assembly machine sizes, attitudes, and configurations, as well asrecycling of modules.

Automated assembly machines are typically categorized by their basicconfiguration as either linear or rotary. Generally, the linear machinesoffer more flexibility and often can produce a more economic use ofspace. The typical linear machine will utilize a carrier belt or chainto cycle work pieces mounted on fixtures sequentially between successiveworkstations where various process/assembly/test operations areperformed thereon. Quite often, an assembly machine will be designed andbuilt to operate on a particular product or group of products and 1)once those workpieces are removed from the stream of commerce, 2) themachine has a portion in need of repair/replacement, or 3) a workstationneeds to be added, the assembly machine becomes scrap.

This problem has been successfully addressed in commonly assigned U.S.Pat. Nos. 5,904,242; 6,273,635; and 6,299,392 which are herebyincorporated by reference. In those patents, an assembly machine havingversatile module construction enables the building blocks of theassembly machine to be reconfigured into a totally different layout, ifneed be, to accommodate future workpieces and workstation requirements.These modular machines, sold under the trademark AGILE ASSEMBLY, havemet with worldwide acceptance in the market place. The precisionmachining of the modules allows them to be easily assembled and theT-keys permit screwless assembly and attachment using common key nut andbolt sizes.

The present invention comprises a reconfigurable assembly machine, saidmachine comprising: a light-weight module configured as a rectangularframe member having four generally open sides, two opposing sides havingpairs of spaced apart inverted T-shaped channels for permittingattachment using precision key and T-nut fasteners, the intermediateadjacent sides having at least one through opening; two end walls eachwith an open center portion to permit electrical/hydraulic lines to passthere through; a supporting spine having a narrow support sectionunderlying the light-weight module and having a maximum width which isless than a maximum width of the module; whereby the light-weight moduleweighs no more than 80 lbs and, in some cases only 50 pounds, and isreadily manipulated by one person. The preferred length of the module is18″, or 450 mm.

The assembly machine further comprises a support frame including anarrow spine member, the spine underlying the light-weight module andhaving a maximum width less than a maximum width of the module. Thecomponents of the supporting spine are equipped with integral T-slotsand T-bar fasteners, as described above, enabling their fastenerlessassembly, as well as attachment thereto and detachment therefrom.

Various other features, advantages, and characteristics of the presentinvention will become apparent after a reading of the following detaileddescription.

BRIEF DESCRIPTION OF THE DRAWINGS

The preferred embodiment(s) of the present invention is/are described inconjunction with the associated drawings in which like features areindicated with like reference numerals and in which

FIG. 1 is a perspective front view of a first embodiment of theinterchangeable module used to construct the assembly machine of thepresent invention;

FIG. 2 is a side view of a first embodiment of the assembly machine ofthe present invention in which the modules provide an over/under layout;and,

FIG. 3 is a perspective view of a second embodiment of the assemblymachine of the present invention in which the modules provide a carouselconfiguration.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENT(S)

A first embodiment of the assembly machine of the present invention isdepicted in FIG. 2 generally at 20. Assembly machine 20 is constructedof a plurality of light-weight modules 30 assembled end-to-end to definethe operational length of assembly machine 20. Module 30 is generallyrectangular in cross section, having two sides 32 with a dimension d₁and two sides 34 with a dimension d₂, where, preferably, d₁>d₂ perhapsas much as 50% greater, although d₁=d₂ is a possible alternative. Thetwo sides 32 are generally entirely open, each with T-slots 36 formedtherein to permit attachment of elements using T-nuts as has beendisclosed in U.S. Pat. No. 6,036,003. The tolerances regarding thecasting and machining of module 30 is rigidly maintained, as with thelarger modules described in the '003 patent. The distinction from theteachings of that patent include the smaller, light weight module andthe inclusion of T-slots 36 on both opposing sides 32. In addition, bothopposing sides 34 have two openings 35 created by reinforcing column 36a. Tapped holes 37 are provided in sides 34 for purposes which will bediscussed hereinafter. T-slots 36 provide means for attaching supportstructure 13, and the like. The versatile, open construction of module30 permits its alternative use to construct an over/under conveyorlayout of the type shown in FIG. 2 or the carousel layout depicted inFIG. 3, a feature not available with the AGILE ASSEMBLY of the previouspatents.

The two ends 38 have openings 39. Openings in sides 32, 34 and ends 38permit ready access to run electrical and hydraulic lines 11, as neededfor various applications. In this first embodiment, conveyor 40 isdriven by motor 45 around driven pulley or stationary guide 46, each ofwhich has a horizontal rotational axis. Conveyor 40 is made ofindividual plates 42 which are hingedly interconnected.

The smaller module 30 requires a support 50′ best seen in FIG. 3.Support 50′ includes a spine 52′ extending horizontally and having amaximum lateral dimension which is less than dimension d₁. Spine 52′ isshown having laterally extending stabilizing legs 54′ attached to spine52′ by engaging a conventional T-nut (not shown) in T-slots 55′ and 55a′ and in T-slots 57′ and 57 a′. Stabilizing legs 54′ are identified asAGILEDOCK. Spine 52′ is connected to one of the sides 32′ by supportblocks 53′ using the T-slots 36. In this second embodiment, conveyor 40′has a drive module 16′ including an electric motor 18′, an indexing geardrive assembly 21′, and a driven pulley 46′ which rotates about avertical axis. Inner and outer plates 48′ sandwich shorter plate 52′ toprovide a slot 56′ into which the edge of conveyor plates 42′ arereceived and by which structure the plates 42′ are guided. Plates 48′and 52′ are attached to sides 34 by fasteners which are received intapped holes 37. Plates 42′ have a plurality of tapped holes 44′ whichprovide means by which workpiece supports (not shown) may be attached tothe conveyor 40′ so that they may move supported workpieces from stationto station for various machining/assembly operations. AGILE APRON 58′ issecured about the periphery of assembly machine 20 by inserting T-nutsinto T-slots 36 L′ and 37 U′ and, by virtue of the upper T-slot 36 U′and the two lower slots 36 L′, provide the ability to attach/suspendcomponents 15′ thereon and there beneath, respectively.

The assembly machine of the present invention is constructed of aplurality of modules 30 of sufficiently light weight (<80 lbs, certainmodules weighing only 50 lbs) which are assembled end-to-end toconstruct a machine for performing particular desired operations on aseries of workpieces. The modular construction permits the assemblymachine to be reconfigured as needed should operational alterationsrequire it, including, but not limited to, the cannibalization of themachine with the modules being usable in constructing a machine havingentirely different characteristics.

Various changes, alternatives and modifications will become apparent toone of ordinary skill in the art following a reading of the foregoingspecification. It is intended that any such changes, alternatives andmodifications as fall within the scope of the appended claims beconsidered part of the present invention.

1. A multiple station linear machine, said linear machine comprising: a)a drive section; b) an end section; c) at least one interchangeablemodule having an open architecture design, said at least oneinterchangeable module having: i) a plurality of openings positionedtherein such that said at least one interchangeable module can besecurely fastened and connected end-to-end to two other modules orsections in a generally linear direction, said at least oneinterchangeable module being connected to two elements selected from agroup consisting of said drive section, said end section and anothersaid interchangeable module; ii) a first maximum lateral dimension whichis equal to a second and a third maximum lateral dimension of said twoelements to which said at least one interchangeable module is connected;iii) a substantially open top wall and a substantially open bottom wall;iv) two lateral side walls each having at least one opening; v) at leasttwo end walls extending between said two lateral side walls, each saidend wall having an open center portion for permitting pass through in anaxial direction; d) an endless conveyor being driven by said drivesection to cycle work pieces sequentially between successive workstationpositions and having a plurality of link plates that are hingedlyinterconnected, said link plates being guided to pass in a slot providedby a structure including said two opposing sides of said at least oneinterchangeable module; and e) a support structure positioning saiddrive section, said end section and said at least one interchangeablemodule above an underlying support surface, said support structureincluding stabilizing elements, said support structure having sufficientlength to extend a distance from a first point beneath said drivesection to a second point beneath said end section whereby saidlight-weight module weighs no more than 80 lbs and said linear machineis readily assembled by one person.
 2. The linear machine of claim 1wherein said module has a length of approximately 18″.
 3. The linearmachine of claim 2 wherein said linear machine comprises a plurality ofsaid identical interchangeable modules.
 4. The linear machine of claim 1wherein said at least one interchangeable module has a weight of lessthan 80 lbs.
 5. The linear machine of claim 1 wherein said at least oneinterchangeable module has a weight of approximately 50 lbs.
 6. Thelinear machine of claim 1 wherein said at least one interchangeablemodule is configured as a rectangular frame member and further comprisestwo opposing sides having pairs of spaced apart inverted T-shapedchannels for permitting attachment using T-nut fasteners, and two endwalls each with an open center portion to permit electrical/hydrauliclines to pass there through.
 7. The linear machine of claim 1 whereinsaid support structure comprises a supporting spine having a narrowsupport section underlying said at least one interchangeable module andhaving a width which is less than a maximum width of said at least oneinterchangeable module.
 8. The linear machine of claim 1 wherein saidmodules and sections are configured as a carousel.
 9. The linear machineof claim 1 wherein said modules and sections are configured in anover/under layout.
 10. The linear machine of claim 1 wherein each ofsaid two lateral sides has at least two openings separated by avertically extending column.